Delhi, India
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It is hard to imagine how the requirement for quality and reliability of welds, economy and the ecological demand placed on today is production methods could be met without the modern production engineering of ultrasonic welding.
As a joining process for industrial thermoplastics, the ultrasonic method is very well proven in practise. Particularly in the production of mass- produced parts, the process offers definite advantage over previous methods.
Roop Telsonic Ultrasonix Limited offers wide selection of welding equipment and installation which with respect to generator performance, range of welding force, frequency of operation and possible uses, efficiently satisfies your specific application requirements.
As a joining process for industrial thermoplastics, the ultrasonic method is very well proven in practice. Particularly in the production of mass- produced parts, the process offers definite advantage over previous methods such as for instance high strength, clean weld seams, fast processing time, extremely low rejection rates and low energy consumption. In addition, this technique can be used successfully for riveting, forming, stacking as well as embedding of metal parts into thermoplastic materials.
Each ultrasonic welding installation comprises the following main components:
The Generator is the heart of every ultrasonic welding system, its function being to supply the transducer with an alternating current of a given ultrasonic frequency. This is then converted by the transducer into mechanical / ultrasonic vibrations which are finally transmitted via, the booster and sonotrode to the item being welded.
Unique Features
Precise time setting with least count of 0.001 second, thus avoiding over welding, deformation, reduction of production rate and excess consumption of power.
Additional ultrasonic vibration at the end of cycle resulting into removal of particles from horn.
Self diagnosis-Microprocessor allows operator to rectify the system.
Automatic tuning of horn & horn life indication, easy capacity upgradation, amplitude setting without changing the booster.
Energy mode option in addition to time mode allowing precise setting of energy as per job requirement.
Spin Welding as the name implies, is a friction welding technique to join thermoplastic parts. It is essential the parts to be joined or atleast their joint areas must be circular for this method of joining to be used. A shallow Machining groove (tongue & groove) is desirable to index the two parts and to provide a uniform bearing surface.
With one part held stationary, either vertically or Horizontally, in a special fixture, the other is rotated at 100-4000 rpm with enough pressure applied to keep the parts in contact with each other. The heat generated in friction is used to bring the surfaces to a sealing temperature. When sufficient melt is obtained, the spinning stops and the pressure is increased to distribute the melt and also to squeeze out excessive melt, completing the general process.
Application Fields
Any circular part made out of thermoplastics, especially for Nylon, PP & Polyethylene Group, Cream Jar, Hair Oil Bottle, Container Lid, Casserole.
The Ultrasonic hand welder "Handystar" is ideal for small welding, riveting and inserting operations using thermoplastic materials; where manual assembly is required. The very compact instrument is suitable for small series application and laboratory.
A further application is spot welding and staking of large parts which require a large degree of mobility of the welding equipment. The operation is very simple. because the operating frequency is 35 kHz, noise emissions are usually no problem. The equipment can therefore be used in any environment.
Generator
Technical Specifications
Features
Ultrasonic can be switch on as per requirement up to Weld time ( 0.001 Sec. to 9, 999 Sec)
The building of special purpose customized machines is RTUL's specialty (Especially for the automobile sector). For many years, we have designed and built systems, which cater to the precise demands of the customer.
Customized Solutions For Complex Projects
For large/complex components, systems with multi converter design (with mother/daughter horns) are available as per specific requirements.
Multiconverter units are frequently used in the welding of large-area, asymmetrical or very precise plastic parts. For example, it is used in automobile and apparatus engineering or with toys. The advantage of the multiconverter system lies in the construction of small, simple sonotrodes which facilitates to optimize the weld quality along the whole weld contour due to local targeting.
Multiple welding heads with compound sonotrodes The robust construction of the USP3000 welding press and maximum clamping force of 3000 N allows the use of up to three 20 kHz oscillating systems with large, complex mother/daughter sonotrodes. The multi-converter welding head is shown as a single oscillating system as a snap-in unit and can be replaced as required by another welding head at any time without any great expense of time in a quick-change process.
ROOPTELSONIC offers high power/high precision equipment for wire splicing and linear welding process. Our Rotary Ultrasonic Welding Head is available for continuous assembly operations which has been a revolution in the solar thermal Industry.
Ultrasonic metal welding is appropriate for the assembly of similar and dissimilar non-ferrous metals.
The primary advantage of this welding technique is that it provides exceptionally short welding times, no filler metals requirements, very low electrical contact resistance and helium-tight welds. Surfaces that are suitable for this type of welding are limited to small areas and restricted to points, line or circular weld patterns.
